2013r Repair manual.pdf

(12932 KB) Pobierz
REPAIR MANUAL
2013
450 SX‑F EU
450 SX‑F FACTORY EDITION EU
450 SX‑F USA
450 SX‑F FACTORY EDITION USA
450 XC-F USA
Art. no. 3206145en
INTRODUCTION
It is important that you read this repair manual carefully and completely before starting work.
INTRODUCTION
1
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of supply.
© 2013 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS
TABLE OF CONTENTS
2
Assembling the fork legs (All SX‑F USA
models)..........................................................
6.31 Assembling the fork legs (XC‑F) ........................
6.32 Bleeding and filling the cartridge......................
6.33 Filling the cartridge with nitrogen .....................
6.34 Greasing the steering head bearing ...................
6.35 Removing the lower triple clamp.......................
6.36 Installing the lower triple clamp .......................
6.37 Checking the steering head bearing play............
6.38 Adjusting the play of the steering head
bearing ..........................................................
7
HANDLEBAR, CONTROLS...........................................
7.1
Handlebar position..........................................
7.2
Adjusting the handlebar position ......................
7.3
Adjusting the basic position of the clutch
lever ..............................................................
7.4
Checking the throttle cable routing ...................
7.5
Checking the play in the throttle cable ..............
7.6
Adjusting the play in the throttle cable..............
8
SHOCK ABSORBER, SWINGARM ................................
8.1
Adjusting the high-speed compression
damping of the shock absorber.........................
8.2
Adjusting the low-speed compression damping
of the shock absorber ......................................
8.3
Adjusting the rebound damping of the shock
absorber.........................................................
8.4
Measuring rear wheel sag unloaded...................
8.5
Checking the static sag of the shock absorber ....
8.6
Checking the riding sag of the shock absorber....
8.7
Adjusting the spring preload of the shock
absorber.........................................................
8.8
Adjusting the riding sag ...................................
8.9
Removing the shock absorber ...........................
8.10 Installing the shock absorber............................
8.11 Checking the shock absorber linkage.................
8.12 Servicing the shock absorber............................
8.13 Removing the spring........................................
8.14 Disassembling the damper ...............................
8.15 Disassembling the piston rod ...........................
8.16 Disassembling the seal ring retainer..................
8.17 Changing the pilot bushing ..............................
8.18 Checking the damper ......................................
8.19 Removing the heim joint..................................
8.20 Installing the heim joint...................................
8.21 Assembling the seal ring retainer ......................
8.22 Assembling the piston rod................................
8.23 Assembling the damper ...................................
8.24 Bleeding and filling the damper .......................
8.25 Filling the damper with nitrogen .......................
8.26 Installing the spring (All SX‑F EU models) .........
8.27 Installing the spring (All USA models)...............
9
EXHAUST ..................................................................
9.1
Removing the manifold....................................
9.2
Installing the manifold ....................................
9.3
Removing the main silencer .............................
9.4
Installing the main silencer..............................
9.5
Changing the glass fiber yarn filling of the
main silencer..................................................
10 AIR FILTER ...............................................................
10.1 Removing the air filter box lid ..........................
10.2 Installing the air filter box lid ...........................
10.3 Removing the air filter .....................................
6.30
1
2
3
4
5
6
MEANS OF REPRESENTATION ..................................... 6
1.1
Symbols used ................................................... 6
1.2
Formats used.................................................... 6
SAFETY ADVICE........................................................... 7
2.1
Repair Manual .................................................. 7
2.2
Safety advice.................................................... 7
2.3
Degrees of risk and symbols ............................... 7
2.4
Work rules........................................................ 7
IMPORTANT NOTES..................................................... 8
3.1
Guarantee, warranty .......................................... 8
3.2
Operating and auxiliary substances ..................... 8
3.3
Spare parts, accessories .................................... 8
3.4
Figures ............................................................ 8
SERIAL NUMBERS ...................................................... 9
4.1
Chassis number ................................................ 9
4.2
Type label ........................................................ 9
4.3
Engine number ................................................. 9
4.4
Fork part number .............................................. 9
4.5
Shock absorber part number .............................. 9
MOTORCYCLE ........................................................... 10
5.1
Raising the motorcycle with the lift stand.......... 10
5.2
Removing the motorcycle from the lift stand...... 10
5.3
Starting.......................................................... 11
5.4
Starting the motorcycle for a check................... 11
FORK, TRIPLE CLAMP ............................................... 12
6.1
Adjusting the compression damping of the
fork ............................................................... 12
6.2
Adjusting the rebound damping of the fork ........ 12
6.3
Bleeding the fork legs...................................... 13
6.4
Cleaning the dust boots of the fork legs............. 13
6.5
Loosening the fork protection ........................... 13
6.6
Positioning the fork protection.......................... 14
6.7
Removing the fork legs .................................... 14
6.8
Installing the fork legs ..................................... 14
6.9
Removing the fork protector ............................. 15
6.10 Installing the fork protector.............................. 15
6.11 Conducting major fork service .......................... 15
6.12 Conducting minor fork service .......................... 16
6.13 Disassembling the fork legs.............................. 16
6.14 Disassembling the cartridge ............................. 19
6.15 Disassembling the piston rod ........................... 21
6.16 Disassembling the screw cap with the
membrane holder............................................ 22
6.17 Disassembling the screw sleeve ........................ 23
6.18 Checking the fork legs (All SX‑F EU models)...... 24
6.19 Checking the fork legs (All SX‑F USA models).... 25
6.20 Checking the fork legs (XC‑F) ........................... 27
6.21 Checking the fork legs - during a minor fork
service (All SX‑F EU models)............................ 28
6.22 Checking the fork legs - during a minor fork
service (All SX‑F USA models).......................... 29
6.23 Checking the fork legs - during a minor fork
service (XC‑F) ................................................. 31
6.24 Changing the pilot bushing .............................. 32
6.25 Assembling the screw sleeve ............................ 33
6.26 Assembling the screw cap with the membrane
holder ............................................................ 33
6.27 Assembling the piston rod................................ 34
6.28 Assembling the cartridge ................................. 35
6.29 Assembling the fork legs (All SX‑F EU
models).......................................................... 37
40
44
47
48
49
49
50
51
52
53
53
53
53
54
54
54
56
56
56
57
58
58
58
59
59
60
61
62
64
64
65
66
67
68
68
69
70
71
71
73
75
77
78
79
80
80
80
81
81
81
83
83
83
83
TABLE OF CONTENTS
10.4 Installing the air filter...................................... 84
10.5 Cleaning the air filter and air filter box .............. 84
10.6 Sealing the air filter box .................................. 85
10.7 Securing the air filter box lid............................ 85
FUEL TANK, SEAT, TRIM ........................................... 86
11.1 Opening the filler cap...................................... 86
11.2 Closing the filler cap ....................................... 86
11.3 Removing the seat .......................................... 87
11.4 Mounting the seat ........................................... 87
11.5 Removing the fuel tank.................................... 87
11.6 Installing the fuel tank .................................... 88
11.7 Checking the fuel pressure............................... 89
11.8 Changing the fuel pump .................................. 90
11.9 Changing the fuel filter.................................... 92
11.10 Changing the fuel screen ................................. 94
MASK, FENDER......................................................... 96
12.1 Removing the front fender ............................... 96
12.2 Installing the front fender ................................ 96
12.3 Removing the start number plate ...................... 96
12.4 Installing the start number plate....................... 97
WHEELS ................................................................... 98
13.1 Checking the tire air pressure........................... 98
13.2 Checking the tire condition .............................. 98
13.3 Checking the brake discs ................................. 98
13.4 Checking the spoke tension.............................. 99
13.5 Front wheel .................................................... 99
13.5.1
Removing the front wheel ............................ 99
13.5.2
Installing the front wheel ........................... 100
13.5.3
Removing the brake disc of the front
brake ....................................................... 101
13.5.4
Installing the brake disc of the front
brake ....................................................... 101
13.6 Rear wheel ................................................... 102
13.6.1
Removing the rear wheel ........................... 102
13.6.2
Installing the rear wheel ............................ 102
13.6.3
Removing the brake disc of the rear
brake ....................................................... 103
13.6.4
Installing the brake disc of the rear brake.... 103
13.6.5
Checking the chain tension........................ 103
13.6.6
Adjusting the chain tension ....................... 104
13.6.7
Adjusting the chain guide .......................... 105
13.6.8
Checking the chain, rear sprocket, engine
sprocket and chain guide........................... 105
13.6.9
Checking for chain dirt accumulation.......... 107
13.6.10 Cleaning the chain .................................... 107
WIRING HARNESS, BATTERY................................... 108
14.1 Changing the main fuse ................................. 108
14.2 Removing the battery .................................... 109
14.3 Installing the battery ..................................... 109
14.4 Charging the battery ...................................... 110
14.5 Checking the charging voltage ........................ 111
14.6 Checking the quiescent current ...................... 111
14.7 Checking the capacitor .................................. 111
14.8 Checking the starter relay .............................. 112
BRAKE SYSTEM ...................................................... 114
15.1 Checking the front brake linings ..................... 114
15.2 Changing the front brake linings ..................... 114
15.3 Checking the free travel of the hand brake
lever ............................................................ 115
15.4 Adjusting the basic position of the hand
brake lever ................................................... 116
15.5 Checking the front brake fluid level ................ 116
Adding front brake fluid.................................
Changing the front brake fluid ........................
Checking the rear brake linings ......................
Changing the rear brake linings ......................
Checking the free travel of foot brake lever ......
Adjusting the basic position of the foot brake
lever ............................................................
15.12 Checking the rear brake fluid level..................
15.13 Adding rear brake fluid ..................................
15.14 Changing the rear brake fluid .........................
16 ENGINE ..................................................................
16.1 Removing the engine.....................................
16.2 Installing the engine......................................
16.3 Engine disassembly.......................................
16.3.1
Preparations .............................................
16.3.2
Draining the engine oil ..............................
16.3.3
Removing the clutch push rod....................
16.3.4
Removing the oil filter ...............................
16.3.5
Removing the starter motor........................
16.3.6
Removing the spark plug ...........................
16.3.7
Removing the valve cover...........................
16.3.8
Removing the alternator cover ....................
16.3.9
Positioning the engine at ignition top dead
center......................................................
16.3.10 Removing the timing chain tensioner ..........
16.3.11 Removing the camshaft .............................
16.3.12 Removing the cylinder head .......................
16.3.13 Removing the piston .................................
16.3.14 Removing the rotor....................................
16.3.15 Removing the timing chain ........................
16.3.16 Removing the ignition pulse generator ........
16.3.17 Removing the suction pump.......................
16.3.18 Removing the water pump cover.................
16.3.19 Removing the clutch cover.........................
16.3.20 Removing the clutch discs .........................
16.3.21 Removing the outer clutch hub ..................
16.3.22 Removing the torque limiter.......................
16.3.23 Removing the starter idler gear...................
16.3.24 Removing the shift shaft............................
16.3.25 Removing the shift drum locating unit ........
16.3.26 Removing the locking lever ........................
16.3.27 Removing the force pump..........................
16.3.28 Removing the primary gear ........................
16.3.29 Removing the freewheel gear .....................
16.3.30 Removing the left engine case section ........
16.3.31 Removing the shift rails.............................
16.3.32 Removing the shift drum ...........................
16.3.33 Removing the shift forks............................
16.3.34 Removing the transmission shafts...............
16.3.35 Removing the crankshaft ...........................
16.4 Work on individual parts ................................
16.4.1
Work on the right section of the engine
case ........................................................
16.4.2
Work on the left section of the engine
case ........................................................
16.4.3
Removing the oil pressure regulator valve ....
16.4.4
Checking spring length of oil pressure
regulator valve ..........................................
16.4.5
Installing the oil pressure regulator valve.....
16.4.6
Changing the crankshaft seal ring in the
clutch cover .............................................
16.4.7
Removing the water pump .........................
15.6
15.7
15.8
15.9
15.10
15.11
3
117
118
119
119
120
121
121
122
122
124
124
129
135
135
135
136
136
136
136
137
137
137
138
138
139
139
139
140
140
141
141
141
142
143
144
144
144
144
144
145
146
146
146
147
147
148
148
149
150
150
151
152
152
153
153
153
11
12
13
14
15

Plik z chomika:

Inne pliki z tego folderu:

Inne foldery tego chomika:

Zgłoś jeśli naruszono regulamin